N13881

Part: LINE — BROKEN (NR 1 ANTI ICE) · airframe 44,519 hrs · 44,651 cycles

THE FIRE DETECTOR LOOP AND MASTER CAUTION ILLUMINATED AND NR 1 ENGINE FIRE INDICATION CAME ON DURING CLIMB OUT OF BOS. QRH PROCEDURES WERE FOLLOWED AND ALL LIGHTS WENT OUT. THE AIRCRAFT WAS RETURNED TO BOS WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND NOSE COWL ANTI-ICE LINE BROKEN AND REAR LT ANTI-ICE TUBE DENTED. BOTH LINES WERE REMOVED AND REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD. MAINTENANCE WAS PERFORMED IAW MM 75-10-2, 75-10-03, AND 26-10-00.

Part: SKIN — CRACKED (VERTICAL STAB) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND A 1.8 INCH CRACK IN VERTICAL STABILIZER SKIN AT BASE OF STABILIZER, STA 1437, LT SIDE. A 4 INCH CRACK WAS FOUND IN VERTICAL STABILIZER SKIN AT BASE OF STABILIZER, STA 1437, RT SIDE. REPAIR DOUBLERS WERE INSTALLED AT EACH LOCATION IAW ECRA 5340-01345.

Part: SLIDE — WILL NOT TEST (TAILCONE) · airframe 43,782 hrs · 43,827 cycles

THE AFT TAILCONE SLIDE FAILED EMERGENCY SLIDE LIGHTS FUNCTIONAL TEST. THE SLIDE WAS REMOVED AND REPLACED IAW MM 25-62-00.

Part: SKIN — CRACKED (FUSELAGE) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND A 1 INCH CRACK IN RT FUSELAGE EXTERIOR SKIN AT STA 1437 BETWEEN LONGERON 3R AND 4R. THE CRACKED AREA OF SKIN WAS CUT OUT AND A REPAIR WAS INSTALLED IAW ECRA 5330-02972.

Part: FLOORBEAM — CORRODED (FUSELAGE) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND FLOORBEAM WEB AND FITTINGS CORRODED IN E/E COMPARTMENT AT LT SIDE, STA 160. THE CORRODED AREA WAS CUT OUT AND A REPAIR WAS INSTALLED IAW ECRA 5310-04025.

Part: SKIN — CRACKED (FUSELAGE) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND TWO 1 INCH CRACKS IN LT FUSELAGE EXTERIOR SKIN AT STA 1437 BETWEEN LONGERONS 3L AND 4L. THE CRACKED AREA OF SKIN WAS CUT OUT AND A REPAIR WAS INSTALLED IAW ECRA 5330-02973.

Part: LONGERON — CORRODED (FUSELAGE) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND LONGERON 22R CORRODED IN FORWARD BAGGAGE BIN AT STA 228. THE CORRODED SECTION OF LONGERON WAS CUT OUT AND A NEW SECTION WAS SPLICED IN IAW SRM 53-02, FIGURE 18.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND A .5 INCH CRACK IN SKIN CLIP AT LT LAV WALL, STA 1309 BETWEEN LONGERONS 13L AND 14L. THE SKIN CLIP WAS REMOVED AND REPLACED IAW SRM 51-30-2.

Part: SHEAR TIE — CRACKED (STA 1307) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND A 1.5 INCH CRACK IN FRAME TO FUSELAGE SKIN CLIP AT STA 1307 BETWEEN STRINGER 15R AND 16R. A NEW SKIN CLIP WAS INSTALLED IAW SRM 51-30-5.

Part: SKIN — DENTED (CARGO DOOR) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND THE AFT CARGO DOOR EXTERNAL SKIN DENTED APPROXIMATELY 16 INCHES FROM AFT EDGE OF DOOR BETWEEN NR 1 AND 2 BEAMS. A DOUBLER AND FILLER WERE INSTALLED IAW SRM 52-05, FIGURE 2.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND LEFT O/B SEAT TRACK CORRODED AROUND FASTENER HOLES AT STA 1150 - 1174. THE CORRODED SECTION OF TRACK WAS CUT OUT AND A NEW SECTION WAS INSTALLED IAW SRM 53-05, FIGURE 4F.

Part: SPLICE — CRACKED (LONGERON) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND A 3 INCH CRACK IN LONGERON 4L SPLICE AT STA 1193 - 1212. REPLACED WITH FABRICATED SPLICE IAW SRM 51-30-0.

Part: SHEAR TIE — CRACKED (FUSELAGE) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND A 1 INCH CRACK IN FRAME TO FUSELAGE SKIN CLIP AT STA 1307 BETWEEN STRINGER 15L AND 16L. THE SKIN CLIP WAS REMOVED AND REPLACED IAW SRM 51-30-5.

Part: SPLICE — CRACKED (LONGERON) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND THREE .5 INCH CRACKS IN LONGERON SPLICE AT STA 1098 - 1117, LONGERON 1L TO 3L AND TWO .5 INCH CRACKS WERE FOUND IN LONGERON SPLICE AT STA 1193-1212, L1L. THE SPLICES WERE REMOVED AND REPLACED IAW SRM 51-30-2 AND 51-30-5.

Part: SEAT TRACK — CORRODED (FUSELAGE) · airframe 43,782 hrs · 43,827 cycles

INSPECTION FOUND RIGHT I/B SEAT TRACK CORRODED AT STA 229. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 51-30-2.

Part: LIGHT — INOPERATIVE (CABIN) · airframe 43,441 hrs · 43,480 cycles

INSPECTION FOUND THE L-1 DOOR EMERGENCY PORTABLE LIGHT ASSEMBLY INOPERATIVE. THE EMERGENCY PORTABLE LIGHT WAS REMOVED AND REPLACED AND OPERATION CHECKED GOOD.

Part: STRUT — REQD SERVICE (NOSE GEAR)

THE NOSE GEAR WOULD NOT RETRACT AFTER TAKEOFF FROM EWR. QRH PROCEDURES WERE ACCOMPLISHED AND THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NOSE GEAR STRUT AT 100 PSI. THE STRUT WAS SERVICED IAW MM 32-21-02. THE GEAR WAS SWUNG SEVERAL TIMES AND OPERATION CHECKED GOOD.

Part: UPLOCK — BROKEN (RT MLG)

THE RT MLG UNSAFE LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION LEAVING EWR. THE LANDING GEAR WAS CYCLED AND THE LIGHT EXTINGUISHED. THE FLIGHT CONTINUED TO BOS WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND A BROKEN SPRING ON UPLOCK AND DOOR LATCH MECHANISM. THE SPRING WAS REPLACED. A PSEU BITE WAS PERFORMED IAW MM 32-60-04 AND OPERATION CHECKED GOOD.

Part: TARGET — LOOSE (LDG GEAR DOOR)

THE GEAR DOOR OPEN LIGHT DID NOT EXTINGUISH AFTER GEAR RETRACTION. WHEN THE GEAR WAS EXTENDED FOR LANDING, THE GEAR DOOR OPEN LIGHT REMAINED ON. THE GEAR WAS CYCLED AND THE LIGHT WENT OUT. MAINTENANCE FOUND THE DOOR PROXIMITY SWITCH TARGET DAMAGED/LOOSE. THE TARGET WAS FASTENED INTO POSITION USING A HI-LOCK RIVET. GEAR INDICATIONS CHECKED GOOD.

Part: SPRING — BROKEN (NLG)

A LOUD SNAP SOUND WAS HEARD COMING FROM NOSE GEAR AREA WHEN GEAR WAS EXTENDED ON APPROACH TO EWR. ALL THREE GREEN GEAR LIGHTS CAME ON AND THE GEAR DOOR OPEN LIGHT WAS EXTINGUISHED. THE AIRCRAFT LANDED SAFELY WITH GEAR WORKING NORMALLY AND THE AIRCRAFT TAXIIED TO THE GATE. MAINTENANCE FOUND THE RT UPPER LOCK LINK EXTENSION SPRING FOR NLG BROKEN. THE SPRING WAS REMOVED AND REPLACED. THE GEAR WAS SWUNG AND OPERATION CHECKED GOOD IAW MM 32-21-03.

Part: CIRCUIT BREAKER — FAILED (FWD GALLEY)

A BURNING ELECTRICAL SMELL WAS DETECTED AT THE FORWARD FLIGHT ATTENDANT PANEL WHILE ON FINAL APPROACH. THERE WAS NO VISIBLE SMOKE. THE AIRCRAFT LANDED AT EWR WITHOUT INCIDENT. THE CIRCUIT BREAKER PANELS IN COCKPIT BEHIND JUMPSEAT AND THE E AND E COMPARTMENT WERE INSPECTED. THE ENGINES WERE RUN AND VARIOUS POWER SOURCES WERE OPERATED. NO DEFECTS WERE FOUND WITH ALL SYSTEMS CHECKING GOOD. MAINTENANCE FOUND THE COFFEEMAKER CIRCUIT BREAKER IN FORWARD GALLEY HAD SIGNS OF BURNING. THE CIRCUIT BREAKER WAS REMOVED AND REPLACED AND OPERATIONAL CHECKS WERE GOOD.

Part: ANGLE — CORRODED (BAGGAGE DOORWAY)

INSPECTION FOUND AFT BAGGAGE BIN DOOR JAMB Z-ANGLE CORRODED. REPAIRED IAW SRM 53-05, FIGURE 63.

Part: TURBINE — FAILED (APU)

THE APU WAS STARTED AFTER LANDING IN EWR AND RAN NORMALLY FOR A WHILE AND THEN FLAMED OUT. THE APU WOULD NOT RESTART. MAINTENANCE FOUND AN UNCONTAINED TURBINE WHEEL SEPARATION. THE SHROUD DID NOT CONTAIN THE TURBINE WHEEL WHICH CAUSED DAMAGE TO THE APU FIREWALL. THE APU WAS REMOVED AND REPLACED IAW MM 49-10-00. A SMALL HOLE FOUND IN THE APU FIREWALL WAS REPAIRED. APU OPERATION CHECKED NORMAL WITH NO LEAKS NOTED. *S/D* INVESTIGATION REVEALED THAT THE CAUSE OF TURBINE WHEEL FAILURE WAS DUE TO AN INCLUSION CREATED IN THE TURBINE WHEEL DURING THE MANUFACTURING PROCESS.

Part: FIRE DET MOD — INOPERATIVE (NR 1 ENGINE)

THE AIRCRAFT HAD A HISTORY OF THE NR 1 ENGINE A-LOOP FIRE WARNING LIGHT ILLUMINATING IN FLIGHT. TWO A-LOOP CONNECTORS: P1-826 AND P1-827 WERE REPLACED. THE NR 1 ENGINE FIRE DETECTION MODULE WAS REMOVED AND REPLACED IAW MM 26-10-03. AN OPERATIONAL CHECK OF THE NR 1 ENGINE FIRE DETECTION SYSTEM WAS PERFORMED WITH NO DEFECTS NOTED.

Part: STRUT — INOPERATIVE (NLG)

THE NOSE GEAR WOULD NOT RETRACT AFTER TAKEOFF FROM BOS. RECYLING PROCEDURES WERE COMPLIED WITH AND THE AIRCRAFT WENT INTO GROUND MODE. THE GEAR REMAINED EXTENDED AND THE AIRCRAFT CONTINUED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NLG OUTER CYLINDER AT FAULT. THE NLG OUTER CYLINDER WAS REMOVED AND REPLACED. IN ADDITION, A FULL SERVICE OF THE NLG SHOCK STRUT WAS PERFORMED IAW MM 32-21-02, PAGE 301.

Part: BEARING — FAILED (NLG)

A LOUD GRINDING NOISE CAME FROM THE NOSE WHEEL AREA UPON TOUCHDOWN ON LANDING AT BOS. MAINTENANCE FOUND THE LT NOSE WHEEL INNER BEARING HAD FAILED AND DAMAGED THE AXLE. THE LT AND RT NOSE WHEELS WERE REMOVED AND REPLACED. IN ADDITION, THE NOSE GEAR PISTON STRUT AND SEALS WERE REMOVED AND REPLACED IAW MM 32-00-01, LEAK CHECKS WERE GOOD. THE NOSE GEAR WAS SWUNG AND OPERATION CHECKED GOOD.

Part: HYD LINE — RUPTURED (AUX PUMP)

THE RT HYDRAULIC SYSTEM PRESSURE AND QUANTITY DROPPED TO ZERO AFTER SELECTING FLAPS TO 15 DEGREES ON APPROACH. THE CHECKLIST PROCEDURES FOR LANDING WITH THE RIGHT HYDRAULIC SYSTEM INOPERATIVE WERE COMPLIED WITH AND THE AIRCRAFT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE HYDRAULIC PRESSURE LINE ON AUX PUMP RUPTURED. THE HYDRAULIC LINE WAS REPLACED. THE HYDRAULIC SYSTEM WAS SERVICED AND LEAK CHECKS WERE GOOD.

Part: BULB — FAILED (LT MLG)

WHEN GEAR WAS EXTENDED FOR LANDING ON APPROACH, THE GREEN LANDING GEAR DOWN INDICATION LIGHT DID NOT ILLUMINATE. THE CREW RELAMPED THE INDICATOR LIGHT DURING A GO-AROUND AND THE INDICATION WAS GOOD. MAINTENANCE FOUND BULB ON LEFT GREEN LANDING GEAR DOWN INDICATOR BURNED OUT. THE BULB WAS REPLACED.

Part: DEFUEL VALVE — OPEN (RT WING)

DURING CLIMB, CREW NOTICE FUEL LEAKING FROM RT WING. ALSO, HIGH FUEL USEAGE FROM RT ENGINE. AIRCRAFT THEN CAME OUT OF TRIM. RETURN TO EWR AND MAINTENANCE FOUND DEFUEL VALVE IN OPEN POSITION AS WELL AS FUELING PANEL DOOR. CYCLE FUEL VALVE AND OPS CHECK GOOD AS PER MM 28-20-00, RAN ALL ENGINES, OPS CHECK GOOD NO FUTHER LEAKAGE.

Part: POWER SUPPLY — INOPERATIVE (OVERWING EXIT)

EXTERIOR EMERGENCY OVERWING EXIT LIGHTS INOPERATIVE. REMOVED AND REPLACED EMERGENCY LIGHT POWER SUPPLY AND BATTERY.

Part: ENGINE — FAILED (NR 1)

THE NR 1 ENGINE EPR WENT TO ZERO ACCOMPANIED BY A LOUD BANG AT 5,000 FEET WITH CLIMB POWER LEAVING EWR. THE NR 1 ENGINE WAS SHUT DOWN AND THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. THE NR 1 ENGINE WAS REMOVED AND REPLACED. LEAK AND OPERATIONAL CHECKS WERE GOOD. *S/D* SHOP FINDINGS REVEALED T-2 VANE FAILURE AS PRIMARY CAUSE.

Part: TRANS RECT — INOPERATIVE (FWD E/E COMPT)

AN ELECTRICAL ODOR WAS MOMENTARILY OBSERVED IN THE FORWARD GALLEY WHILE IN FLIGHT. UPON INVESTIGATION THE RIGHT DC TRANSFER RELAY WAS FOUND TRIPPED AND THE RIGHT DC LOAD METER READ ZERO. THE TRANSFER CIRCUIT BREAKER WAS NOT RESET AND THE ODOR WENT AWAY. THE AIRCRAFT LANDED AT EWR WITHOUT FURTHER PROBLEM. MAINTENANCE FOUND THE RIGHT NR 1 TRANSFORMER RECTIFIER AT FAULT. THE TRANSFORMER RECTIFIER WAS REMOVED AND REPLACED.

Part: INTERCOSTAL — CRACKED (PAX CABIN DOOR)

INSPECTION FOUND A 1 INCH CRACK IN RADIUS OF MAIN CABIN DOOR INTERCOSTAL. THE CRACK WAS LOCATED AFT OF HANDLE TORQUE SHAFT. THE INTERCOSTAL WAS REPLACED IAW SRM 51-30-2 AND 51-30-5.

Part: FRAME — CRACKED (BS 1463)

INSPECTION FOUND A 6 INCH CRACK IN CANTED BELT FRAME AT STA 1463, LONGERON 2L. A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-01.

Part: FLR SUPPORT — CORRODED (FWD ENTRY)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT FORWARD ENTRY PANEL F. THE FLOOR SUPPORT WAS REMOVED AND REPLACED IAW SRM 51-30-2.

Part: FLOOR SUPPORT — CORRODED (BS 148-200)

INSPECTION FOUND FLOOR SUPPORT CORRODED AT FORWARD ENTRY BETWEEN PANELS G AND H, STA 148 TO 200. A NEW SUPPORT WAS FABRICATED AND INSTALLED IAW SRM 51-30-1 AND 51-30-2.

Part: ANGLE — CRACKED (BS 984-1003)

INSPECTION FOUND A 1.5 INCH CRACK IN LOWER RADIUS OF EXTERNAL ANGLE AT STA 984 TO 1003, LONGERON 20L. THE AREA WAS REPAIRED IAW ECRA 5310-03277 AND SRM 53-02.

Part: FLOOR SUPPORT — CORRODED (BS 718)

INSPECTION FOUND FLOOR SUPPORT AT STA 718 CORRODED AROUND NUTPLATE. THE FLOOR SUPPORT WAS REPLACED IAW SRM 51-30-2.

Part: DOOR PAN — DENTED (SERVICE DOOR)

INSPECTION FOUND FORWARD SERVICE DOOR PAN DENTED AT BAYONET FITTING. A DOUBLER WAS FABRICATED AND INSTALLED AND DOOR STOP WAS REPLACED IAW SRM 53-05, FIGURE 42.

Part: SUPPORT — CRACKED (GRD SPOILER)

INSPECTION FOUND A 1 INCH CRACK AT FORWARD ATTACH FASTENER OF RT GROUND SPOILER O/B CROSS BRACE SUPPORT. A CROSS BRACE WAS INSTALLED IAW ECRA 5710-01733.

Part: DOUBLER — CRACKED (BS 100)

INSPECTION FOUND A .1875 INCH CRACK IN DOUBLER AT NOSE WHEEL WELL LEFT AFT DOOR AFT HINGE CUTOUT, STA 100. A DOUBLER WAS INSTALLED IAW SRM 53-05, FIGURE 62.

Part: DUCT — LOOSE (LT PACK)

FLT 1875 - THE CABIN PRESS BEGAN TO CLIMB SLOWLY WHILE AT CRUISE ALT FL 310 AND WAS ACCOMPANIED BY FLOW LIGHT COMING ON, WHILE EN ROUTE. SYS WAS SWITCHED TO STANDBY W/O REMEDY. WHILE DESCENDING TO 10,000 FT THE CABIN RATE OF CLIMB INCREASED AND THE 02 MASKS DEPLOYED. THE A/C WAS DIVERTED TO TPA WHERE IT LANDED SAFELY. MX FOUND RUBBER DUCT TO DISCHARGE SIDE OF LT PACK HAD PARTIALLY SLID OFF DUE TO LOOSE CLAMP. NEITHER THE DUCT OR CLAMP WERE DAMAGED. THE RUBBER DUCT WAS REPOSITIONED AND RESECURED. THE A/C WAS PRESS AND NO LEAKS FOUND. THE O2 MASKS DID NOT DEPLOY AT ROWS 2, 4, 31, AND 32 LT, 31 RT, OR FWD F/A STA. ALL PAX AND F/A 02 GENS REPLACED. PSU DROP CK PERFORMED IAW MM 35-00-00 AND OPS CK GOOD.(M)

Part: HYD LINE — LEAKING (RUDDER)

FLT NR 0378 - BOS - THE RIGHT HYDRAULIC QUANTITY BEGAN TO DROP RAPAIDLY WHILE CLIMBING THROUGH 1700 FEET LEAVING EWR, BOUND FOR BOS. THE FLIGHT MANUAL PROCEDURES WERE FOLLOWED AND THE LANDING GEAR WAS EXTENDED MANUALLY FOR AN UNEVENTFUL LANDING AT BOS. MAINTENANCE FOUND THE RUDDER POWER HYDRAULIC SUPPLY LINE LEAKING AT B-NUT. THE LINE WAS REMOVED AND A HYDRAULIC FLEX LINE WAS INSTALLED. A DIP WAS ISSUED TO REPLACE THE FLEX LINE WITHIN 500 FLIGHTS OR 1200 FLIGHT HOURS, WHICHEVER OCCURS FIRST. LEAK CHECKS WERE GOOD. (M)

Part: ENGINE — FAILED (NR 2)

MCO - FLT 0554 - THE NR 2 ENGINE FAILED WITH A LOUD POP AND FLAME SEEN IN THE EXHAUST DURING TAKEOFF ROLL AT 60 KNOTS. THE TAKEOFF WAS REJECTED AND THE AIRCRAFT WAS RETURNED TO THE GATE. MAINTENANCE REMOVED AND REPLACED THE NR 2 ENGINE. THE SDR WILL REMAIN OPEN FOR PART INFORMATION PENDING INVESTIGATION. (X)

Part: STATOR SUPPORT — FAILED (NR 2 ENGINE)

FLT NR 0554 - MCO - THE NR 2 ENGNIE FAILED WITH A LOUD POP AND FLAME SEEN IN THE EXHAUST DURING TAKEOFF ROLL AT 60 KNOTS. THE TAKEOFF WAS REJECTED AND THE AIRCRAFT WAS RETURNED TO THE GATE. MAINTENANCE REMOVED AND REPLACED THE NR 2 ENGINE. TEARDOWN REVEALED A CRACKED/BROKEN 8TH STAGE STATOR SUPPORT SHELF. (M)

Part: EEL WIRING — BROKEN (CABIN)

FLT NR 0323 - EWR - INSPECTION FOUND SEVERAL SECTIONS OF EMERGENCY AISLE PATH LIGHTS INOPERATIVE. MAINTENANCE FOUND BROKEN WIRING AT SEVERAL LOCATIONS. THE WIRING WAS SPLICED AND A NEW HARNESS WAS INSTALLED AT REAR ENTRY DOOR. OPERATION OF THE AISLE PATH LIGHTING WAS RESTORED. (M)

Part: EEL BATTERIES — DISCHARGED (CABIN)

FLT NR 0327 - EWR - THE OVERHEAD EMERGENCY LIGHTS IN FIRST CLASS SECTION OF CABIN WOULD NOT ILLUMINATE WHEN TESTED DURING A PREFLIGHT CHECK. THE BATTERIES FOR THE OVERHEAD EMERGENCY LIGHTS WERE REMOVED AND REPLACED AND OPERATION OF THE LIGHTS WAS RESTORED. (Z)